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Reassembly [02/2014 - 11/2016]: Procedure

  1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side) 
    1. Using SST, a steel plate and a press, install a new front drive shaft bearing.
      GTY433479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Steel Plate
      • SST: 09527-10011 
      NOTE:

      The bearing should be completely installed.

    2. Using a snap ring expander, install a new drive shaft hole snap ring.
      GTY441319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Install the drive shaft hole snap ring securely.

  2. INSTALL FRONT DRIVE SHAFT DUST COVER RH 
    1. Using a steel plate and a press, install a new front drive shaft dust cover RH until the dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

      Dimension (A)

      110.5 mm (4.35 in.)

      GTY453831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Steel Plate
      NOTE:
      • The front drive shaft dust cover RH should be completely installed.
      • Be careful not to damage the front drive shaft dust cover RH.
  3. INSTALL FRONT DRIVE SHAFT DUST COVER LH 
    1. Using a steel plate and a press, install a new front drive shaft dust cover LH.
      GTY441037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Steel Plate
      NOTE:
      • The front drive shaft dust cover LH should be completely installed.
      • Be careful not to damage the front drive shaft dust cover LH.
  4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT 
    1. Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.
      GTY447139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    2. Install new parts to the front drive outboard joint shaft assembly in the following order:
      GTY425440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Drive Outboard Joint Shaft Assembly
      *2 Front No. 2 Axle Outboard Joint Boot Clamp
      *3 Front Axle Outboard Joint Boot
      *4 Front Axle Outboard Joint Boot Clamp
      Outboard joint side
      Inboard joint side
      1. Front No. 2 axle outboard joint boot clamp
      2. Front axle outboard joint boot
      3. Front axle outboard joint boot clamp
    3. Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease.

      Standard Grease Capacity

      174 g (6.14 oz)

    4. Install the front axle outboard joint boot to the front drive outboard joint shaft assembly groove.
      NOTE:
      • Do not allow grease to adhere to the boot clamp track of the outboard joint boot.
      • Keep the inside of the outboard joint boot free of foreign matter.
  5. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot.
    3. Place SST to the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY425855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    4. Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.
      GTY455139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is outside the specified range, retighten SST.

  6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP 
    1. Install the front axle outboard joint boot clamp to the front axle outboard joint boot.
    2. Place SST to the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY438538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    3. Tighten SST so that the front axle outboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    4. Remove SST.
    5. Using SST, measure the clearance of the front axle outboard joint boot clamp.
      GTY437912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is outside the specified range, retighten SST.

  7. INSTALL FRONT DRIVE SHAFT DAMPER 
    1. w/ 1 Clamp:
      1. Install the front drive shaft damper to the front drive outboard joint shaft assembly.
        GTY453559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Set the dimension (A) as specified below.

        Dimension (A)

        231.0 to 235.0 mm (9.10 to 9.25 in.)

      3. Hold the drive shaft in a vise between aluminum plates.
        NOTE:

        Do not overtighten the vise.

      4. Install a new front drive shaft damper clamp to the front drive shaft damper.
        NOTE:

        Be sure to install the clamp in the correct position.

      5. Place SST to the front drive shaft damper clamp, press it against the damper and slightly tighten SST.
        GTY182473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09521-24010 
      6. Tighten SST so that the front drive shaft damper clamp is pinched.
        NOTE:

        Do not overtighten SST.

      7. Remove SST.
      8. Using SST, measure the clearance of the front drive shaft damper clamp.
        GTY205527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09240-00020 

        Clearance

        0.5 to 1.5 mm (0.0197 to 0.0590 in.)

        If the clearance is outside the specified range, retighten SST.

    2. w/ 2 Clamps:
      1. Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.
        GTY554856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Front Drive Shaft Damper Clamp
        *2 Front Drive Shaft Damper
      2. Set the dimension (A) as specified below.

        Dimension (A)

        229.9 to 233.9 mm (9.06 to 9.20 in.)

      3. Install the 2 front drive shaft damper clamps to the front drive shaft damper.
        NOTE:

        Make sure to install the clamps in the correct position.

      4. Using needle nose pliers, install the 2 front drive shaft damper clamps.
        GTY429228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY 
    1. Install new parts to the front drive outboard joint shaft assembly in the following order:
      GTY440271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Axle Inboard Joint Boot Clamp
      *2 Front Axle Inboard Joint Boot
      *3 Front No. 2 Axle Inboard Joint Boot Clamp
      *a Protective Tape
      Outboard joint side
      Inboard joint side
      1. Front axle inboard joint boot clamp
      2. Front axle inboard joint boot
      3. Front No. 2 axle inboard joint boot clamp
    2. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    3. Remove the protective tape.
    4. Align the matchmarks and install the tripod joint to the front drive outboard joint shaft assembly.
      NOTE:

      Face the serrated side of the tripod joint outward and install it to the outboard joint end.

      GTY426614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    5. Align the matchmarks placed before removal.
    6. Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly.
      NOTE:
      • Do not tap the rollers.
      • Keep the tripod joint free of foreign matter.
      • Be sure to install the tripod joint in the correct direction.
    7. Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.
      GTY426949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Pack the front drive inboard joint assembly and front axle inboard boot with grease.

      Standard Grease Capacity

      165 g (5.82 oz)

    9. Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.
      GTY451119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
  9. INSTALL FRONT AXLE INBOARD JOINT BOOT 
    1. Install the front axle inboard joint boot to the front drive inboard joint assembly.
    2. Check whether the drive shaft dimension (A) is within specification.
      GTY429366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for LH Side
      *B for RH Side

      Dimension (A)

      for LH Side 593.34 mm (1.95 ft.)
      for RH Side 934.64 mm (3.07 ft.)
  10. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP 
    1. Hold the drive shaft in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install the front axle inboard joint boot clamp to the front axle inboard joint boot.
    3. Place SST to the front axle inboard joint boot clamp, press it against the boot and slightly tighten SST.
      • SST: 09521-24010 
      GTY431947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten SST so that the front axle inboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    5. Remove SST.
    6. Using SST, measure the clearance of the front axle inboard joint boot clamp.
      • SST: 09240-00020 

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is outside the specified range, retighten SST.

      GTY452770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP 
    1. Install the front No. 2 axle inboard joint boot clamp to the front axle inboard joint boot.
    2. Place SST to the front No. 2 axle inboard joint boot clamp, press it against the boot and slightly tighten SST.
      GTY440515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09521-24010 
    3. Tighten SST so that the front No. 2 axle inboard joint boot clamp is pinched.
      NOTE:

      Do not overtighten SST.

    4. Remove SST.
    5. Using SST, measure the clearance of the front No. 2 axle inboard joint boot clamp.
      GTY438716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09240-00020 

      Clearance

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

      If the clearance is outside the specified range, retighten SST.

  12. INSPECT FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSPECTION [02/2014 - 11/2016] 

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